The posts I'll be using are 100x75 so not a regular size. However, you have given me a few thoughts about how I could possible simplify what I'm trying to do. Might even contact them or find out who manufactures them to see if they can do a special run for me.The sample you have purchased can be purchased quite cheaply for square posts of varying sizes. Can you not adapt your design to use standard sizes?
Galvanised Fence Square Rectangular Post Panel Clips Clamp Selection List | eBay
Selection List. You Choice Size and Quantity. Poczta Polska Depence from weight. We sent by.www.ebay.co.uk
It is actually possible to bend parts like that in a press brake, by putting extra bends into places that should be strait edges and the pressing the extra bends out again afterwards.Most folders or press brakes won’t bend to that shape unless in two halves and then welded together though.
Looks like a fat joist hanger?A bit crude as I am away from home & access to proper drawing tools, but something like this might work - View attachment 1069489
Almost, but not quite...Looks like a fat joist hanger?
Going bigger wouldn't add much to the cost as it is the cutting and bends that have the biggest impact at these sizes, but I guess that the neater and probably cheaper option is the simple U type bracket with the timber packer and pinch bolt between the post and board.Thanks for drawing that up @TheTallGuy. My initial thoughts on it are that it might be a bit more expensive than that as the boards are going to be 150mm deep so the bracket depth would be near 200mm in total due to the clamp position.
If the clamp could be hidden from the board side would be a neater solution and would allow for a much narrower bracket.
It's a bit of a puzzle. An alternative would be to use 80mm x 150mm C Square bolts to clamp it on with. Care would be needed to ensure it didn't look rough and it might need powder coating to blend it in a bit. All expense no matter what way you approach it.